US20050270671A1 - Optical reflection plate and method of producing the same - Google Patents

Optical reflection plate and method of producing the same Download PDF

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Publication number
US20050270671A1
US20050270671A1 US10/518,535 US51853505A US2005270671A1 US 20050270671 A1 US20050270671 A1 US 20050270671A1 US 51853505 A US51853505 A US 51853505A US 2005270671 A1 US2005270671 A1 US 2005270671A1
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US
United States
Prior art keywords
reflector plate
sheet
film
light
cuts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/518,535
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English (en)
Inventor
Yoshiyuki Nousou
Nobuyuki Morita
Kazuya Nagashima
Takaaki Kemmotsu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Furukawa Electric Co Ltd
Original Assignee
Furukawa Electric Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Furukawa Electric Co Ltd filed Critical Furukawa Electric Co Ltd
Assigned to FURUKAWA ELECTRIC CO., LTD., THE reassignment FURUKAWA ELECTRIC CO., LTD., THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KEMMOTSU, TAKAAKI, MORITA, NOBUYUKI, NAGASHIMA, KAZUYA, NOUSOU, YOSHIYUKI
Publication of US20050270671A1 publication Critical patent/US20050270671A1/en
Abandoned legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/08—Mirrors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/10—Construction

Definitions

  • the present invention relates to a technique for forming a three-dimensional light reflector plate adapted to allow thickness reduction and enhancement of the brightness and efficiency of backlights and lighting boxes for use with illumination signboards, liquid crystal displays, lighting fixtures, and the like.
  • Conventionally proposed light reflector plates for use with illumination signboards, liquid crystal displays, lighting fixtures, and the like include those fabricated as follows: a light-reflecting film having a thickness of about 200 ⁇ m is laminated on an aluminum or steel plate, and the resultant reflector plate material is formed into a three-dimensional shape to thereby yield a light reflector plate; and a reflector plate of resin is formed into a three-dimensional shape to thereby yield a light reflector plate (refer to, for example, Japanese Patent Application Laid-Open (kokai) No. 6-260010).
  • fabricating the former light reflector plate fabricated in a manner such that a light-reflecting film is laminated on an aluminum or steel plate, and the resultant reflector plate material is formed into a three-dimensional shape—involves a number of press dies and a number of working steps, resulting in high die cost, increased man-hours, and high cost of working.
  • Fabrication of the latter light reflector plate fabricated in a manner such that a reflector plate of resin is formed into a three-dimensional shape—involves thermal molding that uses a molding die or the like.
  • this fabrication method involves poor working accuracy caused by, for example, shrinkage after thermal molding, as well as high molding die cost and cost of working.
  • the present invention has been accomplished in view of the foregoing, and an object of the invention is to provide a light reflector plate including a bent light-reflecting film or sheet of resin and having the following advantages A to D:
  • the present invention provides the following methods 1 to 5 for manufacturing a light reflector plate:
  • the present invention provides a light reflector plate characterized by being manufactured by the method for manufacturing a light reflector plate as described above in any one of 1 to 5.
  • the light reflector plate of the present invention is a light reflector plate characterized by being fabricated by a method such that narrow cuts are intermittently formed in a light-reflecting plastic foam film or sheet along a straight line in such a manner as to penetrate from one side surface of the film or sheet to the opposite side surface thereof, and subsequently the film or sheet is bent along the cuts, as well as a light reflector plate fabricated such that the thus-obtained light reflector plate is fixed on an aluminum or steel plate by the method described above in 4.
  • a reflector plate material including an aluminum or steel plate having a thickness of about 200 ⁇ m and a light-reflecting film laminated on the aluminum or steel plate
  • fabrication involves a number of press dies and a number of working steps.
  • die cost is high, and the number of working man-hours is large, resulting in high cost of working.
  • a thermal molding method that uses a molding die or the like has been employed.
  • this method involves poor working accuracy caused by, for example, shrinkage after thermal molding, as well as high molding die cost and cost of working.
  • cuts are formed in a plastic foam film or sheet in the form of perforations in rows, whereby the film or sheet can be readily and accurately formed into a three-dimensional shape by bending it inward and outward along the cuts.
  • the need to use expensive dies is eliminated, and bending work can be performed at low cost by use of simple jigs or the like.
  • the shape of a three-dimensional light reflector plate formed through the bending work can be retained practically, readily, and accurately.
  • FIG. 1 is a view showing an example of cuts formed in a sheet before bending, accompanied by an enlarged view of cuts.
  • FIG. 2 is a view showing an example of the shape of the sheet after bending.
  • FIG. 3 is a view illustrating the shape of a bent sheet and the position of fluorescent lamps by example.
  • FIG. 4 is a view showing an example state before attachment of a bent sheet article to an aluminum plate.
  • FIG. 5 is a view showing an example state after attachment of the bent sheet article to the aluminum plate.
  • FIG. 6 is a view showing an example state in which the sheet is clamped by bending a standing claw of the aluminum plate.
  • FIG. 7 is a view showing an example of a formed aluminum article before attachment of a film thereto.
  • FIG. 8 is a view showing an example of cuts formed in a film before bending, accompanied by an enlarged view of cuts.
  • FIG. 9 is a view showing an example state in which the film is clamped by bending a standing claw of the formed aluminum plate.
  • FIG. 10 is a view showing an example state before attachment of a bent film article to the formed aluminum plate.
  • FIG. 11 is a view showing an example state after attachment of the bent film article to the formed aluminum plate.
  • narrow cuts are formed in a light-reflecting plastic foam film or sheet in the form of perforations in straight rows in such a manner as to penetrate from one side surface of the film or sheet to the opposite side surface thereof, and subsequently the film or sheet is bent inward and outward along the cuts in the form of perforations in rows, whereby the planar film or sheet can be readily formed into a three-dimensional shape.
  • the film or sheet is a thermoplastic polyester or cyclopolyolefin film or sheet having therein a number of fine bubbles or pores having an average diameter not greater than 50 ⁇ m.
  • each of the cuts to be formed in the plastic foam film or sheet has a width not greater than 3 mm and a length not longer than 10 mm, and an uncut portion located between two adjacent cuts has a length not shorter than 1 mm.
  • an uncut portion located between intermittently arranged cuts preferably has a length not shorter than 1 mm.
  • the length of a cut is determined on the basis of the following: use of a commercially available cutting tool that has cutting blades arranged intermittently at a pitch not greater than 10 mm so as to cut a row of perforations is inexpensive and practical.
  • an unfoamed plastic sheet or film involves the following problem: in the case of involving a large number of bending lines or a large area subjected to bending (e.g., the case shown in FIGS. 1 and 2 , which will be described later), forming cut portions in the form of perforations in rows in a single operation of cutting may fail to provide uniform cutting over the entire surface of the sheet or film, since the sheet or film is hard. As a result, the sheet or film may not be properly bent along perforations.
  • a foamed body is soft and easy to cut, thus allowing easy formation of cuts therein even in the case of involving a large number of bending lines or a large area subjected to bending.
  • a step of bending the above-mentioned light-reflecting plastic foam film or sheet along the cuts to thereby obtain a bent reflector plate there is performed a step of inserting, into a hole or slit portion provided on the bent reflector plate, a claw-like standing portion having a width of 1 mm to 5 mm and a length of 3 mm to 20 mm and formed on an aluminum or steel plate having a thickness not greater than 1 mm, and bending the claw-like standing portion to thereby fixedly join together the bent reflector plate and the aluminum or steel plate.
  • a claw-like bend portion is provided on an aluminum or steel plate; after insertion of the claw into a corresponding hole or slit portion provided on the film or sheet, the claw is, for example, bent forward or backward to thereby attach the film or sheet to the aluminum or steel plate.
  • the thickness of the aluminum or steel plate is not greater than 1 mm; the width of the claw is 1 mm to 5 mm, and the length of the claw is 3 mm to 20 mm; and the claw is formed through slit cutting because of easiness of machining.
  • claw clamp portions formed through insertion of the claw-like standing portions into the corresponding holes or slit portions mentioned above are arranged at a pitch not greater than 300 mm. That is, by arranging the clamping claws in a planar direction at a pitch not greater than 300 mm, even when the completed reflector plate is put into actual used or tested at high temperature, at high humidity, or under thermal cycle conditions, the shape can be retained with a desired dimensional accuracy.
  • the bent film or sheet can be attached to the aluminum or steel plate by means of pressure sensitive adhesive double coated tape.
  • this method is disadvantageous in that positioning between the bent film or sheet and the metal plate to which the film or sheet is to be attached is difficult. Attachment by screws is also possible.
  • cost tends to increase, and thus the method becomes impractical.
  • a light-reflecting plastic foam sheet having a thickness of 1 mm and an internal bubble diameter not greater than 50 ⁇ m is commercially available and is formed as follows: an extruded sheet of thermoplastic polyester is impregnated with carbon dioxide gas under high pressure, and the resultant sheet is foamed through application of heat. Also commercially available is a light-reflecting plastic foam film formed from cyclopolyolefin and having a thickness of 0.5 mm and an internal bubble diameter not greater than 50 ⁇ m.
  • the examples below are offered to illustrate a method for manufacturing, from the light-reflecting sheet and film and by use of the present invention, a three-dimensional light reflector plate to be placed behind fluorescent lamps that serve as light sources for backlight of a liquid crystal display unit.
  • cuts 4 were formed along straight lines in a polyethylene terephthalate foam sheet 2 formed through foaming fourfold and having an average bubble diameter not greater than 50 ⁇ m and a thickness of 1 mm by use of a band-blade-like punching blade having a thickness of 0.7 mm to 1.42 mm and adapted to punch in a sheet 5-mm-length perforations arranged straight at 5 mm intervals.
  • the foam sheet 2 was bent inward and outward along the cuts so as to form straightly extending angle portions, thereby obtaining a bent reflector plate 6 .
  • FIG. 1 cuts 4 were formed along straight lines in a polyethylene terephthalate foam sheet 2 formed through foaming fourfold and having an average bubble diameter not greater than 50 ⁇ m and a thickness of 1 mm by use of a band-blade-like punching blade having a thickness of 0.7 mm to 1.42 mm and adapted to punch in a sheet 5-mm-length perforations arranged straight at 5 mm intervals.
  • the pitch of the angle portions to be formed through bending was designed to coincide with pitch p of fluorescent lamps 8 for backlight; specifically, such that the crest of an angle portion is located at a substantially middle position between the adjacent fluorescent lamps 8 —at a position located p/2 away from either fluorescent lamp 8 .
  • a die was not used for bending.
  • the angle portions were formed one by one through bending.
  • claw-like standing portions 12 each having a width of 2 mm and a length of 4 mm were formed on a planar aluminum plate 10 having a thickness of 0.8 mm in the vicinity of the foot of each angle portion so as to avoid contact with a fluorescent lamp at the time of application of vibration, and were arranged at a pitch of 250 mm in the longitudinal direction of the angle portions.
  • the claws 12 were inserted into corresponding round holes 14 , which each have a diameter of 3 mm and had been formed beforehand in the reflector plate 6 at positions corresponding to the standing claws 12 of the aluminum plate 10 , as shown in FIG.
  • the claws 12 were bent in such a manner as to clamp the reflector plate 6 .
  • bending the claws 12 in such a direction as to return it toward the original position; i.e., toward the plate side, as shown in FIG. 6 is preferred in order to reduce leakage of light at the time of fluorescent lamps being lit.
  • the film 22 was bent along perforation portions 28 , which correspond to the standing portions 24 of the formed aluminum article 26 .
  • Claw-like standing portions 30 each having a width of 2 mm and a length of 4 mm were formed on the formed aluminum article 26 at a pitch of 200 mm at positions selected so as to avoid contact with a fluorescent lamp at the time of application of vibration.
  • U-shaped slit portions 32 each having a side length of 3 mm as shown in FIG. 9 were formed on the film 22 at positions corresponding to the claws 30 of the formed aluminum article 26 .
  • the claws 30 of the formed aluminum article 26 were inserted into the corresponding slit portions 32 of the bent film 22 .
  • the claws 30 were bent in such a manner as to clamp the film 22 , thereby attaching the film 22 to the formed aluminum article 26 .

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Nonlinear Science (AREA)
  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mathematical Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Optical Elements Other Than Lenses (AREA)
US10/518,535 2002-10-16 2003-10-09 Optical reflection plate and method of producing the same Abandoned US20050270671A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2002301828A JP3890005B2 (ja) 2002-10-16 2002-10-16 光反射板およびその製造方法
JP2002301828 2002-10-16
PCT/JP2003/012956 WO2004036271A1 (ja) 2002-10-16 2003-10-09 光反射板およびその製造方法

Publications (1)

Publication Number Publication Date
US20050270671A1 true US20050270671A1 (en) 2005-12-08

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US10/518,535 Abandoned US20050270671A1 (en) 2002-10-16 2003-10-09 Optical reflection plate and method of producing the same

Country Status (9)

Country Link
US (1) US20050270671A1 (ja)
EP (1) EP1553431A4 (ja)
JP (1) JP3890005B2 (ja)
KR (1) KR20050073462A (ja)
CN (1) CN100349022C (ja)
CA (1) CA2493425C (ja)
HK (1) HK1079574A1 (ja)
TW (1) TWI238238B (ja)
WO (1) WO2004036271A1 (ja)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070139958A1 (en) * 2005-12-21 2007-06-21 Chen-Yi Wu Backlight module
US8623930B2 (en) 2010-08-27 2014-01-07 Furukawa Electric Co., Ltd. Thermoplastic resin foam, method of producing the same, and light reflecting material thereof
WO2017126853A1 (en) * 2016-01-21 2017-07-27 Lg Electronics Inc. Display device
KR20170130782A (ko) * 2016-05-19 2017-11-29 엘지전자 주식회사 백라이트 유닛 및 이를 포함하는 디스플레이 장치
US9989802B2 (en) 2015-01-29 2018-06-05 Samsung Display Co., Ltd. Display device including reflective sheet having cover part
US10371358B2 (en) * 2017-03-06 2019-08-06 Industrial Lighting Products, Llc LED board mounting system for a light fixture

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US7521667B2 (en) 2003-06-23 2009-04-21 Advanced Optical Technologies, Llc Intelligent solid state lighting
US7145125B2 (en) 2003-06-23 2006-12-05 Advanced Optical Technologies, Llc Integrating chamber cone light using LED sources
CN101019047B (zh) 2004-06-21 2010-08-11 出光兴产株式会社 集成背底板的反射器、背光和液晶显示装置
JP2006146010A (ja) * 2004-11-24 2006-06-08 Furukawa Electric Co Ltd:The 光反射板
KR101208339B1 (ko) * 2004-12-17 2012-12-05 마루오 칼슘 가부시키가이샤 다공질 필름용 충전제 및 이 충전제를 배합하여 이루어지는다공질 필름
TW200712568A (en) * 2005-09-02 2007-04-01 Furukawa Electric Co Ltd Light reflection plate
JP2007103154A (ja) 2005-10-04 2007-04-19 Furukawa Electric Co Ltd:The 面光源装置
JP4413842B2 (ja) 2005-10-04 2010-02-10 古河電気工業株式会社 面光源装置
JP2007155892A (ja) * 2005-12-01 2007-06-21 Furukawa Electric Co Ltd:The 光反射板
CN101460779A (zh) 2005-12-21 2009-06-17 科锐Led照明技术公司 照明装置
JP2007199363A (ja) * 2006-01-26 2007-08-09 Furukawa Electric Co Ltd:The 光反射部材およびそれを用いた直下型面発光装置
US7777166B2 (en) 2006-04-21 2010-08-17 Cree, Inc. Solid state luminaires for general illumination including closed loop feedback control
KR101340682B1 (ko) 2006-05-05 2013-12-12 크리, 인코포레이티드 조명 장치
KR100816126B1 (ko) 2006-11-24 2008-03-21 재 동 윤 반사판 제조방법 및 반사판
WO2009012287A1 (en) 2007-07-17 2009-01-22 Cree Led Lighting Solutions, Inc. Optical elements with internal optical features and methods of fabricating same
JP5956641B2 (ja) * 2015-04-20 2016-07-27 サンライト工業株式会社 ナンバープレートの製造方法
JP2017004643A (ja) * 2015-06-05 2017-01-05 シャープ株式会社 照明装置、表示装置及びテレビジョン受信機
EP3185071B1 (en) * 2015-12-23 2019-10-09 Samsung Electronics Co., Ltd. Display apparatus

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US5938317A (en) * 1996-05-29 1999-08-17 Hubbell Incorporated Lighting fixture with internal glare and spill control assembly
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US8130339B2 (en) 2005-12-21 2012-03-06 Chimei Innolux Corporation Backlight module
US20070139958A1 (en) * 2005-12-21 2007-06-21 Chen-Yi Wu Backlight module
US8623930B2 (en) 2010-08-27 2014-01-07 Furukawa Electric Co., Ltd. Thermoplastic resin foam, method of producing the same, and light reflecting material thereof
US9989802B2 (en) 2015-01-29 2018-06-05 Samsung Display Co., Ltd. Display device including reflective sheet having cover part
US10324334B2 (en) 2016-01-21 2019-06-18 Lg Electronics Inc. Display device
WO2017126853A1 (en) * 2016-01-21 2017-07-27 Lg Electronics Inc. Display device
US10768484B2 (en) 2016-01-21 2020-09-08 Lg Electrunecs Inc. Display device
KR20170130782A (ko) * 2016-05-19 2017-11-29 엘지전자 주식회사 백라이트 유닛 및 이를 포함하는 디스플레이 장치
KR102525813B1 (ko) * 2016-05-19 2023-04-26 엘지전자 주식회사 백라이트 유닛 및 이를 포함하는 디스플레이 장치
US10371358B2 (en) * 2017-03-06 2019-08-06 Industrial Lighting Products, Llc LED board mounting system for a light fixture
US10753584B2 (en) 2017-03-06 2020-08-25 Industrial Lighting Products, Llc LED board mounting system for a fixture
US11287113B2 (en) 2017-03-06 2022-03-29 Industrial Lighting Products, Llc LED board mounting system for a fixture
US11739915B2 (en) 2017-03-06 2023-08-29 Industrial Lighting Products, LLC. LED board mounting system for a light fixture

Also Published As

Publication number Publication date
TWI238238B (en) 2005-08-21
CA2493425C (en) 2010-02-02
EP1553431A4 (en) 2006-12-13
CA2493425A1 (en) 2004-04-29
CN100349022C (zh) 2007-11-14
JP2004138715A (ja) 2004-05-13
TW200411138A (en) 2004-07-01
HK1079574A1 (en) 2006-04-07
EP1553431A1 (en) 2005-07-13
KR20050073462A (ko) 2005-07-13
JP3890005B2 (ja) 2007-03-07
WO2004036271A1 (ja) 2004-04-29
CN1703632A (zh) 2005-11-30

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